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Review does not constitute acceptance of Design
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Accepted
☐ 1
Accepted. Proceed with Work and
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Not Accepted. Work May Not
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Name / Signature Date

B IFR 29 MAY 2020 DA RL SN

A IDC 27 MAY 2020 DA RL SN
Rev Status Date Originator Checker Approver Project
Document Title:

FLANGE REPAIR AND SURFACE MACHINING PROCEDURE

Client Project No. Client Document No. Page

Company Project No. Company Document No.

1 of 8
0468 0468-ASOM20-92P1-0006-001

FPSO GUANABARA MV31

 FLANGE REPAIR AND SURFACE
FPSO GUANABARA MV31 MACHINING PROCEDURE
0468-ASOM20-92P1-0006-001, Rev B

RECORD OF AMENDMENT
REVISION SECTION PARAGRAPH DESCRIPTION OF CHANGE
A Interdisciplinary Check
B Issued for Review

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 FLANGE REPAIR AND SURFACE
FPSO GUANABARA MV31 MACHINING PROCEDURE
0468-ASOM20-92P1-0006-001, Rev B

TABLE OF CONTENTS

1. GENERAL REQUIREMENT............................................................................................ 4
2. GENERAL REPAIR PROCEDURE ................................................................................. 4
3. WELDING & MACHINING PROCEDURE OF COMPACT FLANGES
SURFACE ....................................................................................................................... 5
4. REPAIR PROCEDURE OF GELOK FLANGE SURFACE MACHINING ......................... 9

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FPSO GUANABARA MV31 MACHINING PROCEDURE
0468-ASOM20-92P1-0006-001, Rev B

1. GENERAL REQUIREMENT

1.1 ASOM to provide approved welder / consumables in line with current approved WPS,
GTAW filler wire diameter 2.4mm available.
1.2 In the event of welding more than one layer, always ensure the inter-pass temperature
is less than 150 deg C.
1.3 No carbon steel materials to be used including grinding disc except for carbon steel pipe
spools.
1.4 NDT is 100% UT & PT subject to UT probe accessibility.
1.5 For DSS, 100% PMI & Ferrite Count on all welded flanges and hardness test value not
more than 28HRC.
1.6 Official Reports to include pictures of damaged flanges before and after repair.

2. GENERAL REPAIR PROCEDURE

2.1 To inspect the flange damaged area kindly refer to Table 3.1, Table 3.2, Figure A and
Figure B in this procedure.
2.2 To select applicable WPS and qualified welder for welding the damage area.
2.3 After sufficient cleaning and/or grinding done on the damaged area, NDT to be done prior
to commence weld repair.
2.4 After build-up welding on damaged area as per approved WPS completed, a visual
inspection with necessary cleaning and/or grinding is required.
2.5 NDT, PMI & Ferrite test to be done after visual inspection completed.
2.6 After NDT, PMI & Ferrite test approved, flange repair to handover for machining. A pre-
inspection check must be done prior to machining (Refer to Table 3.1, Table 3.2, Figure
A and Figure B in this procedure).
2.7 To set up machining equipment according to flange damaged area.
2.8 To do machining as per required standards (refer to Table 4.1 and Table 4.2 in this
procedure).
2.9 After machining is done, a final inspection by QA/QC and Machining Team including
visual and dimension check. (refer to Table 4.1 and Table 4.2 in this procedure).
2.10 To do pressure test, if applicable (refer to ASOM’s Hydrotest procedure no. 0468-
ASOM20-92P1-0002-001).

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 FLANGE REPAIR AND SURFACE
FPSO GUANABARA MV31 MACHINING PROCEDURE
0468-ASOM20-92P1-0006-001, Rev B

3. WELDING & MACHINING

Compact PROCEDURE
Flange sealingOF COMPACT
surface seat FLANGES SURFACE
3.1 RTJ gouges dimensional tolerance.
The internal and external oblique diameter: ±0.13, Gouges depth: +0.4, Angle of oblique
diameter: 23 ±0.5°, Gouges width: ±0.2.
3.2 Confirm item before processing:
20±0.08°
A. Confirm flange size and pressure class.
B. Confirm whether the damage exceeded the machining height of the flange raised
surface.
C. Direct machining within the residual height range of the base; Excess residual height
shall be machined after welding.
D. Confirm the equipment installation space.
E. To assess construction safety risks.
3.3 Equipment installation.
Take the flange face as the benchmark, adjust the flatness to within 0.1mm; Adjust the
concentricity between the equipment and the flange to within 0.1mm based on the
internal and external oblique diameters.
3.4 Repair procedure of welding flange damage.
For the scratch defect of flange face, the repair plan is as follows:
A. Cleaning: use the grinder to grind the scratched surface
B. Preheat as per the WPS using heating torch on the affected area of flange, at
min.75mm from the edge dents, scratches, scars to remove moisture before
welding.
C. Proceed GTAW Welding 2mm higher than the theoretical size of the defect
complying to approved WPS weld parameters.
D. Machining flange datum face to eliminate measurement error.
E. External inclined diameter: middle diameter of groove + groove width.
F. Inside slope diameter: middle diameter of the groove - width of the groove.
G. Groove depth: after confirming that the remaining dimensions of the groove are
correct, machine the groove depth achieved the standard size.
H. Grind lightly using stainless steel grinding disc, the original outline size of the specific
flange according to the required dimension.
I. PT shall be carried out before and after welding.

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For example, if the inner oblique surface is damaged, the measured diameter and
radius are reduced by 1mm and 0.5mm after turning. In order to guarantee the size,
the outer oblique diameter should be processed at the same time.
Convex platform height20°
should be machined:
= 0.5 / tan (23°) = 1.17mm, therefore, groove depth needs to be machined 1.17mm.
(Note: except that point D is the first processing sequence, the three points of E, F, G
are not required as the standard sequence, and the actual processing surface is the
priority).

Table 3.1. Allowable Defect Depth vs Width Across Face (Metric)

Table 3.2 Damage repair guide

Note: in accordance to NORSOK standard L-005, Section 5.14.7, Table 7.

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Figure A. Flange Surface Damage Assessment: Pits and dents

Gasket seating surface

Pits and dents
Single
Joined
Do not locally polish, grind, or buff seating surface (remove burrs only).
Rd = projected radial distance across seating surface
d = radial measurement between defects
Scattered: rd = the sum of rdi

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Figure B. Flange Surface Damage Assessment: Scratch and Gouges

Scratches and Gouges

Do not locally polish, grind, or buff seating surface (remove burrs only)
Rd = projected radial distance across seating surface

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4. REPAIR PROCEDURE OF GELOK FLANGE SURFACE MACHINING

4.1. See drawing, Flange internal oblique size (No tolerance temporarily)

4.2. Confirm item before processing.

A. Confirm flange size and pressure class.
B. Confirm whether the damage of the inner bevel exceeds the height difference between
the concave surface of the flange.
C. Machining directly within the reinforcement range of the concave; machining beyond
the reinforcement range needs to be carried out after welding.
D. Confirm the equipment installation space (use internal flange facing machine).
E. To assess construction safety risks.
4.3. Equipment installation.
Take the flange face as the benchmark, adjust the flatness to within 0.1mm; adjust the
concentricity between the equipment and the flange to within 0.1mm based on the
internal oblique diameters.
4.4. Repair steps.
A. Machining flange datum face to eliminate measurement error caused by datum level.
B. Adjust the angle (without the angle dimension) and process the inner bevel with a feed
rate of 0.05mm per cutter until the damage of the inner bevel is eliminated (if there

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FPSO GUANABARA MV31 MACHINING PROCEDURE
0468-ASOM20-92P1-0006-001, Rev B

are repair welding spots, first eliminate the repair welding and then confirm the original
dimension for processing).
C. After eliminating the damage point, use the ball gauge and caliper to measure the
diameter expansion value of the inner slope.
D. Rework the flange reference plane to reduce the inner bevel diameter until the original
dimension is restored.
E. Measure and confirm that the size is in place and use oilstone and fine sand to treat
the inner inclined surface so that the finish can achieve better results.
F. Inspect and dismantle the equipment after processing.

Table 4.1 Surface finish for flanges

Note: in accordance to NORSOK standard L-005, Section 5.10, Table 4.

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Table 4.2 Flange dimensional tolerance

Note: in accordance to NORSOK standard L-005, Appendix A, Section A.7, Table A-12.

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